Woodward Vertex-Pro User manual

Installation & Hardware Manual
Vertex-Pro
Motor-Driven Compressor Control
Volume 1
Installation & Hardware
Manual 26489 consists of 2 volumes (26489V1 & 26489V2).
Manual 26489V1

DEFINITIONS
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
DANGER—Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
WARNING—Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION—Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE—Indicates a hazard that could result in property damage only (including
damage to the control).
IMPORTANT—Designates an operating tip or maintenance suggestion.
The engine, turbine, or other type of prime mover should be equipped with an
overspeed shutdown device to protect against runaway or damage to the prime
mover with possible personal injury, loss of life, or property damage.
The overspeed shutdown device must be totally independent of the prime mover
control system. An overtemperature or overpressure shutdown device may also
be needed for safety, as appropriate.
Read this entire manual and all other publications pertaining to the work to be performed before
installing, operating, or servicing this equipment. Practice all plant and safety instructions and
precautions. Failure to follow instructions can cause personal injury and/or property damage.
This publication may have been revised o
r
updated since this copy was produced. To verify that
you have the latest revision, be sure to check the Woodward website:
www.woodward.com/pubs/current.pdf
The revision level is shown at the bottom of the front cover after the publication number. The latest
version of most publications is available at:
www.woodward.com/publications
If your publication is not there, please contact your customer service representative to get the
latest copy.
Any unauthorized modifications to or use of this equipment outside its specified mechanical,
electrical, or other operating limits may cause personal injury and/or property damage, including
damage to the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or
"negligence" within the meaning of the product warranty thereby excluding warranty coverage
for any resulting damage, and (ii) invalidate product certifications or listings.
To prevent damage to a control system that uses an alternator or batter
y
-charging
device, make sure the charging device is turned off before disconnecting the battery
from the system.
To prevent damage to electronic components caused by improper handling, read
and observe the precautions in Woodward manual 82715, Guide for Handling and
Protection of Electronic Controls, Printed Circuit Boards, and Modules.
Woodward Governor Company reserves the right to update any portion of this publication at any time. Information
provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is assumed
by Woodward Governor Company unless otherwise expressly undertaken.
© Woodward 2009
All Rights Reserved

Manual 26489V1 Vertex-Pro Motor-Driven Compressor Control
Woodward i
Contents
REGULATORY COMPLIANCE ....................................................................... IV
ELECTROSTATIC DISCHARGE AWARENESS .................................................VII
CHAPTER 1. GENERAL INFORMATION...........................................................1
1.1—Introduction ....................................................................................................1
1.2—Specifications and Compatibility ....................................................................1
CHAPTER 2. VERTEX-PRO SYSTEMS............................................................2
2.1—Vertex-Pro Configurations .............................................................................2
2.2—Vertex-Pro Redundant ...................................................................................3
2.3—Vertex-Pro Redundant Operation ..................................................................5
2.4—Vertex-Pro Simplex........................................................................................6
2.5—Vertex-Pro Simplex Operation .......................................................................8
2.6—Module Replacement.....................................................................................8
2.7—Latent Fault Detection....................................................................................8
CHAPTER 3. CHASSIS................................................................................10
3.1—MicroNet Plus 8-Slot Chassis ......................................................................10
3.2—Specification.................................................................................................11
3.3—Installation....................................................................................................13
CHAPTER 4. POWER SUPPLIES..................................................................14
4.1—Vertex-Pro Chassis Power Supplies............................................................14
4.2—Installation....................................................................................................16
4.3—Power Supply Troubleshooting....................................................................18
CHAPTER 5. CPUS....................................................................................20
5.1—PowerPC CPU5200 Module (Motorola).......................................................20
CHAPTER 6. DISCRETE I/O MODULES ........................................................31
6.1—Introduction ..................................................................................................31
6.2—48/24 Discrete Combo Module ....................................................................31
CHAPTER 7. ANALOG I/O MODULES ..........................................................38
7.1—Introduction ..................................................................................................38
7.2—Combination I/O Modules ............................................................................38
7.3—24/8 Analog Module.....................................................................................38
7.4—Analog Combo Module (Option) ..................................................................46
CHAPTER 8. FIELD TERMINATION MODULES (FTMS)..................................60
8.1—Introduction ..................................................................................................60
8.2—Analog I/O FTMs..........................................................................................60
8.3—Discrete I/O FTM..........................................................................................65
CHAPTER 9. INSTALLATION AND REPLACEMENT PROCEDURES...................68
9.1—Pre-Installation Information..........................................................................68
9.2—Installation Procedures ................................................................................69
9.3—Replacement Procedures ............................................................................80
CHAPTER 10. SERVICE OPTIONS ...............................................................86
10.1—Product Service Options ............................................................................86
10.2—Woodward Factory Servicing Options .......................................................87
10.3—Returning Equipment for Repair ................................................................88
10.4—Replacement Parts ....................................................................................88
10.5—Engineering Services.................................................................................89
10.6—How to Contact Woodward ........................................................................89
10.7—Technical Assistance .................................................................................90

Vertex-Pro Motor-Driven Compressor Control Manual 26489V1
ii Woodward
Contents
APPENDIX A. MATRIX OF MODULES WITH COMPLIANCE INFORMATION ........91
APPENDIX B. ENVIRONMENTAL SPECIFICATIONS ........................................92
APPENDIX C. DECLARATIONS.....................................................................93
APPENDIX D. ACRONYMS...........................................................................98
Illustrations and Tables
Figure 2-1—Input Flow ...........................................................................................4
Figure 2-2—Output Flow ........................................................................................4
Figure 2-3—Redundant Sensors............................................................................4
Figure 2-4—Input Flow ...........................................................................................7
Figure 2-5—Output Flow ........................................................................................7
Figure 2-6—Redundant Sensors............................................................................7
Figure 2-7—CHAS_STAT Block.............................................................................9
Figure 3-1—MicroNet Plus 8-Slot I/O Chassis .....................................................10
Figure 3-2—MicroNet Plus 8-Slot Chassis...........................................................11
Figure 3-3—Outline Drawing of MicroNet Plus 8-Slot Chassis ............................13
Figure 3-4—Mounting Template of MicroNet Plus 8-Slot I/O Chassis .................13
Figure 4-1—Power Supply Module.......................................................................15
Figure 5-1—CPU Module .....................................................................................21
Figure 5-2—CPU Module Block Diagram.............................................................21
Figure 5-3—CPU Communications Port (DB9F)..................................................25
Figure 5-4—RS-422 Terminator Locations ..........................................................25
Figure 5-5—RS-485 Terminator Locations ..........................................................26
Figure 5-6—Termination and Cable Connection Examples.................................26
Figure 5-7—Preferred Multipoint Wiring Using Shielded Twisted-Pair Cable with
a Separate Signal Ground Wire.......................................................27
Figure 5-8—Alternate Multipoint Wiring Using Shielded Twisted-Pair Cable
without a Separate Signal Ground Wire ..........................................27
Figure 5-9—CPU Service Port (mini-DIN6F)........................................................28
Figure 5-10—CAN Communication Ports (M12 male) .........................................28
Figure 5-11—CAN Communication Connection Example ...................................29
Figure 6-1—Discrete Combo Module...................................................................32
Figure 6-2—Configuration 2, Two 24/12 Discrete FTMs......................................33
Figure 6-3—Discrete Input Interface Wiring to a 24/12 Discrete FTM .................34
Figure 6-4—Relay Output Interface Wiring to a 24/12 Discrete FTM ..................35
Figure 6-5—48/24 Discrete Combo Module Block Diagram ................................36
Figure 7-1—24/8 Analog Module..........................................................................39
Figure 7-2—Simplex System Configuration Example ..........................................41
Figure 7-3—Analog Input Wiring for a 24/8 Analog FTM .....................................42
Figure 7-4—Analog Output Wiring for a 24/8 Analog FTM ..................................43
Figure 7-5—Analog Combo Module.....................................................................46
Figure 7-6—Simplex System Configuration Example ..........................................49
Figure 7-7—MPU/Proximity Interface Wiring to the Analog Combo FTM............50
Figure 7-8—Current Input Wiring for an Analog Combo Module FTM.................52

Manual 26489V1 Vertex-Pro Motor-Driven Compressor Control
Woodward iii
Illustrations and Tables
Figure 7-9—Voltage Input Wiring for an Analog Combo Module FTM ................53
Figure 7-10—Analog Output and Actuator Wiring for an Analog Combo FTM....55
Figure 8-1—24/8 Analog FTM Outline Dimensions .............................................61
Figure 8-2—24/8 Analog FTM Schematic ............................................................62
Figure 8-3—Analog Combo FTM Outline Dimensions.........................................63
Figure 8-4—Analog Combo FTM Schematic .......................................................64
Figure 8-5—24/12 Discrete Module Outline Dimensions .....................................66
Figure 8-6—24/12 Discrete Module Schematic....................................................67
Figure 9-1—MicroNet Power Supply....................................................................70
Figure 9-2—FTM Grounding and Outlines ...........................................................72
Figure 9-3—Shield Termination Diagram Example..............................................73
Figure 9-4—Discrete FTM Grounding Diagram Example ....................................73
Figure 9-5—Bottom Cable Entry Area..................................................................78
Figure 9-6—Door Bonding....................................................................................78
Figure 9-7a—Cable Entry # 1...............................................................................79
Figure 9-7b—Cable Entry # 2...............................................................................79
Figure 9-8—Zoning...............................................................................................80
Table 4-1—MicroNet Plus Power Supply Requirements .....................................17
Table 6-1—LED Indications of Failure .................................................................36
Table 7-1—LED Indications of Failure .................................................................43
Table 7-2—LED Indications of Failure .................................................................55

Vertex-Pro Motor-Driven Compressor Control Manual 26489V1
iv Woodward
Regulatory Compliance
European Compliance for CE Marking
These listings are limited only to those units bearing the CE Marking:
EMC Directive: Declared to 89/336/EEC COUNCIL DIRECTIVE of 03
May 1989 on the approximation of the laws of the
Member States relating to electromagnetic compatibility.
Low Voltage Declared to 73/23/EEC COUNCIL DIRECTIVE of 10
Directive: February 1973 on the harmonization of the laws of the
Member States relating to electrical equipment designed
for use within certain voltage limits.
ATEX – Potentially Declared to 94/9/EC COUNCIL DIRECTIVE of 23 March
Explosive 1994 on the approximation of the laws of the Member
Atmospheres States concerning equipment and protective systems
Directive: intended for use in potentially explosive atmospheres.
Zone 2, Category 3, Group II G, Ex nA [nL] IIC T3 X
Other European and International Compliance
Compliance with the following European Directives or standards does not qualify
this product for application of the CE Marking:
Machinery Compliant as a component with 98/37/EC COUNCIL
Directive: DIRECTIVE of 23 July 1998 on the approximation of the
laws of the Member States relating to machinery.
GOST-R: Certified for use in ordinary locations within the Russian
Federation per GOST-R certificates РОСС US.
US.МЛ03.В00603 and POCC US. US.МЛ03.В00604
This equipment is considered indicator equipment and is not to be
used as metrology equipment. All measurements need to be verified
using calibrated equipment.
North American Compliance
These listings are limited only to those units bearing the UL identification:
UL: UL Listed for Class I, Division 2, Groups A, B, C, & D,
T3A at 65 °C surrounding air temperature. For use in
Canada and the United States.
UL File E156028
The 16-channel relay interface modules are suitable for
ordinary or non-hazardous locations only.
Marine
American Bureau ABS Rules 2002 SVR 4-2-1/7.3, 4-2-1/7.5.1, 4-9-3/17,
of Shipping: 4-9-7/13, 4-9-2/11.7 & 4-9-4/23
Det Norske Veritas: Standard for Certification No. 2.4, 2006:
Temperature Class A, Humidity Class B,
Vibration Class B, and EMC Class A
Lloyd’s Register LR Type Approval Test Specification No. 1,
of Shipping: 2005 for Environmental Categories ENV1 and ENV2

Manual 26489V1 Vertex-Pro Motor-Driven Compressor Control
Woodward v
This equipment is suitable for use in Class I, Division 2, Groups A, B, C, D T3A at
65 °C surrounding air temperature per UL for Canada and US or ordinary
locations only.
This equipment is suitable for use in European Zone 2, Group IIC environments
when installed in an IP54 minimum rated enclosure per self-declaration to EN
60079-15.
Wiring must be in accordance with North American Class I, Division 2, or
European Zone 2, Category 3 wiring methods as applicable, and in accordance
with the authority having jurisdiction.
Product listings are limited only to those units bearing the UL or CE logos.
Special Conditions for Safe Use
A fixed wiring installation is required.
Ground leakage current exceeds 3.5 mA.
Grounding is required by the input PE terminal.
A switch or circuit breaker shall be included in the building installation that is in
close proximity to the equipment and within easy reach of the operator and that is
clearly marked as the disconnecting device for the equipment.
Field wiring must be suitable for at least 80 °C for operating ambient
temperatures expected to exceed 55 °C.
For ATEX compliance, this equipment must be installed in an area providing
adequate protection against the entry of dust or water. A minimum ingress
protection rating of IP54 is required for the enclosure. This enclosure shall also
provide protection against impact according to Sub-Clause 26.3.3.1 of EN60079-
15:2003.
For ATEX compliance, this equipment must be protected externally against
transient disturbances. Provisions shall be made to prevent the power input from
being exceeded by transient disturbances of more than 40% of the rated voltage.
CPU modules contain internal energy limited circuits. These circuits have no
external connections and are not affected by module loading.
CPU modules contain single cell primary batteries. These batteries are not to be
charged and are not customer replaceable.
For environmental specifications, please refer to the appropriate appendix in
Volume 2 of this manual.

Vertex-Pro Motor-Driven Compressor Control Manual 26489V1
vi Woodward
EXPLOSION HAZARD—Do not connect or disconnect while circuit is
live unless area is known to be non-hazardous.
Substitution of components may impair suitability for Class I,
Division 2 applications.
Do not remove or install power supply while circuit is live unless
area is known to be non-hazardous.
Do not remove or install modules while circuit is energized unless
area is known to be non-hazardous.
RISQUE D’EXPLOSION—Ne pas raccorder ni débrancher
tant que l’installation est sous tension, sauf en cas
l’ambiance est décidément non dangereuse.
La substitution de composants peut rendre ce matériel
inacceptable pour les emplacements de Classe I,
applications Division 2.
Ne pas enlever ni installer l’alimentation électrique pendant
que le circuit est sous tension avant de s’assurer que la
zone est non dangereuse.
Ne pas enlever ni installer les cartes pendant que le circuit
est sous tension à moins de se trouver dans un
emplacement non dangereux.

Manual 26489V1 Vertex-Pro Motor-Driven Compressor Control
Woodward vii
Electrostatic Discharge Awareness
All electronic equipment is static-sensitive, some components more than others.
To protect these components from static damage, you must take special
precautions to minimize or eliminate electrostatic discharges.
Follow these precautions when working with or near the control.
1. Before doing maintenance on the electronic control, discharge the static
electricity on your body to ground by touching and holding a grounded metal
object (pipes, cabinets, equipment, etc.).
2. Avoid the build-up of static electricity on your body by not wearing clothing
made of synthetic materials. Wear cotton or cotton-blend materials as much
as possible because these do not store static electric charges as much as
synthetics.
3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam
cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or
folders, plastic bottles, and plastic ash trays) away from the control, the
modules, and the work area as much as possible.
4. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
Do not touch any part of the PCB except the edges.
Do not touch the electrical conductors, the connectors, or the
components with conductive devices or with your hands.
When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.

Vertex-Pro Motor-Driven Compressor Control Manual 26489V1
viii Woodward

Manual 26489V1 Vertex-Pro Motor-Driven Compressor Control
Woodward 1
Chapter 1.
General Information
1.1—Introduction
The Vertex-Pro is a microprocessor-based control with integral application
software designed to control a motor and its one or two-loop compressor load.
Three and four loop compressor stages may be an option for some systems. The
compressor control architecture is patterned after the 505CC-2 compressor
control. The compressor anti-surge control provides the user with a choice
between two algorithms—the standard Woodward anti-surge algorithm or a
universal surge curve design. The standard algorithm compensates for changing
gas/process conditions, while the universal algorithm uses an invariant
coordinate system that is immune to such changes. Like the 505CC-2, the
Vertex-Pro uses configurable software for maximum field flexibility.
The control hardware uses the MicroNet™ Plus. The MicroNet Plus is a 32-bit
microprocessor-based digital and a VME-based controller, modular control
system with redundant or simplex CPU, power supply and I/O module options.
CPUs and I/O modules may be simplex or redundant, depending on customer
requirements. A simplex system can be upgraded to redundant system by simply
adding a second CPU and I/O modules and changing a minor software
configuration. I/O modules allow for hot replacement without removing control
power.
The MicroNet Operating System, together with Woodward’s GAP™ Graphical
Application Program, produces a powerful control environment. Woodward’s
unique rate group structure ensures that control functions will execute
deterministically at rate groups defined by the application engineer. Critical
control loops can be processed within 5 milliseconds. Less critical code is
typically assigned to slower rate groups. The rate group structure prevents the
possibility of changing system dynamics by adding additional code. Control is
always deterministic and predictable.
Communications with the MicroNet platform are available to program and service
the control as well as to interface with other systems (Plant DCS, HMI, etc.).
Application code is generated by use of Woodward’s GAP program or
Woodward’s Ladder Logic programming environment. A service interface allows
the user to view and tune system variables. Several tools are available to provide
this interface (see Engineering and Service Access). Communication protocols
such as TCP/IP, OPC, Modbus®*, and other current designs are included so that
the user can correctly interface the control to existing or new plant level systems.
*—Modbus is a trademark of Schneider Automation Inc.
1.2—Specifications and Compatibility
For environmental specifications and MicroNet compatibility information, please
refer to the appropriate appendix in this manual.

Vertex-Pro Motor-Driven Compressor Control Manual 26489V1
2 Woodward
Chapter 2.
Vertex-Pro Systems
2.1—Vertex-Pro Configurations
The Vertex-Pro controls family is developed around the VME chassis and a CPU
module that goes into the first active slot of the VME chassis. All I/O modules plug
into the remaining slots of the VME chassis.
The Vertex-Pro offers both simplex (single Power-supply, CPU and I/O modules)
and redundant (dual Power-supply, CPU and I/O modules) operation with up to 8
VME slots per chassis. The Vertex-Pro comes with the following options
regarding power supply voltage and cabinets.
System Config Parts Numbe
r
Power Supply Voltage Cabinet
Redundancy 8263-0109 110 Vac/dc x
8262-3026 110 Vac/dc -
8263-0115 24 Vdc x
8262-3028 24 Vdc -
8263-0117 220 Vac x
8262-3030 220 Vac -
Simplex 8263-0110 110 Vac/dc x
8262-3027 110 Vac/dc -
8263-0116 24 Vdc x
8262-3029 24 Vdc -
8263-0118 220 Vac x
8262-3031 220 Vac -
x: with non EMI cabinet
For critical applications requiring increased reliability and availability, users can
order dual-redundant control models, which have manual switch-over and
automatic fail-over capabilities. These redundant control models also allow users
to replace/repair modules and perform program changes while the compressor is
operating on-line, thus greatly improving system availability.
Analog combo modules can be chosen as an option of the
Vertex-Pro. If the analog combo module is chosen, a maximum three
speed signals are directly acceptable from a magnetic pick-up or
proximity probe. Please refer to section 7.4 in this manual for details.

Manual 26489V1 Vertex-Pro Motor-Driven Compressor Control
Woodward 3
2.2—Vertex-Pro Redundant
2.2.1—System Diagram
Vertex-Pro Redundant
MicroNet 8 VME Slot Chassis
Dual CPUs for redundant operation
Motorola PowerPC CPU5200
Redundant I/O modules
Redundant Power
Redundant smart fans
FAN_3 FAN_4
FAN_2FAN_1
24/8 Analog I/O
A3
Blank
A4
Blank
A5
48/24 Discrete I/O
A6
48/24 Discrete I/O
A7
24/8 Analog I/O
A2
2-Slot
Power
Supply
PS1
2-Slot
Power
Supply
PS2
A8
CPU5200
A1
CPU5200
A8
2.2.2—Redundant CPU Theory
The Vertex-Pro control system uses redundant CPU5200 modules that must be
located in the first and last VME slots (A1 and A8). The chassis has a single
motherboard and houses 2 power-supplies, 2 CPUs, and 6 I/O slots. The CPUs
share a single data path to the VME modules and each other.
The CPU5200 module offers high processing capability in a PowerPC
MPC5200 processor with features like dual Ethernet, dual Real Time Network
ports, dual CAN, and a configurable RS-232/RS-422/RS-485 serial port.
Module operating temperature limits are –40 to +85 °C.
In a redundant system, there are two CPU modules, running the same application
program, receiving power from the same pins on the VME backplane, and with access
to the I/O modules over the same VME bus. The CPU modules communicate their
health to each other over the VME bus, and arbitrate for control of the bus. The CPU
which is in slot 1 and in good “health” first, gains control of the I/O modules, and is
called the System Controller or SYSCON. The other CPU is then the backup or
STANDBY CPU. The SYSCON sends all necessary state information to the backup
CPU, allowing it to take control of the I/O modules if the SYSCON fails.
The following conditions will cause a failover from the SYSCON CPU to the backup
STANDBY CPU:
Failure of the on board CPU module power supplies
Failure of the processor core, including the processor, RAM, flash, oscillator,
etc.
Failure of communications between the processor and the FPGA
A watchdog timeout between the CPU module and the FPGA. This would
mean that one of the devices did not respond to the other device, within a
prescribed amount of time.
A reset of the SYSCON CPU, caused by the front panel or remote Resets
An application requested failover
An application stop

Vertex-Pro Motor-Driven Compressor Control Manual 26489V1
4 Woodward
2.2.3—Redundant Power Supplies
Two load sharing power supplies provide redundant power to the motherboard,
CPU and I/O modules. The MicroNet Plus power supplies are 2-slot wide each and
are located at each end of the chassis in the designated PS1 and PS2 slots.
2.2.4—Simplex Inputs and Outputs
Each I/O module has connectors on the faceplate. For analog and discrete I/O,
cables connect the module to a Field Terminal module (FTM). The FTM is used to
connect to the field wiring. For communications on the CPU, FTMs are not used.
Cables are connected directly to the faceplate of the communications on the CPU.
The following diagram shows the flow of analog and discrete inputs from the field
to the application.
Figure 2-1—Input Flow
Figure 2-2—Output Flow
2.2.5—Redundant Inputs and Outputs
One level of redundancy is available. This involves wiring two external input
devices to two separate input channels. See Figure 2-3. In the event of a failed
sensor or a failure in the connection from the sensor to the control, a valid input is
still available
Figure 2-3—Redundant Sensors

Manual 26489V1 Vertex-Pro Motor-Driven Compressor Control
Woodward 5
The second level is wiring two external input devices to two separate I/O modules.
See Figure 2-4. In the event of a failure in one of the sensors, connections, cables,
FTMs, or I/ O modules, a valid input is still available.
2.2.6—Redundant Outputs
Redundancy can be added to the outputs as well. Additional external relays can be
used to prevent a faulted output from affecting the external device. For discrete
outputs, this would require two relays for each output.
The value of redundancy is dependent on the ability of the application to detect the
failure. For analog outputs, current and/or voltage readback is provided. For
discrete outputs, fault detection requires sensing the relay contact state.
2.3—Vertex-Pro Redundant Operation
To use the MicroNet Plus for redundant operation, a CPU must be in the first VME
slot (slot A1) and a CPU must be in the last VME slot (slot A8).
Start-up
Load and start the application on each CPU using AppManager.
If the CPUs are started within 20 seconds of each other they will boot in the
“Redundant” mode.
If the CPUs are not started within 20 seconds of each other the first CPU
started will become the master and the second CPU will have to re-sync to
the running CPU.
If the applications are not the same and both CPUs are started together,
CPU1 (located in slot A1) will be the SYSCON and the backup CPU will be
failed.
Normal Operation (Redundant)
Normally the CPUs will be powered up together and will start running the
application within the 20 second window.
The first CPU to start running the application will remove the WATCHDOG (as
indicated by the red LED on the CPU) and become the SYSCON (as
indicated by the green LED on the CPU).
When the second CPU starts running the application the SYSCON control will
go to CPU1 (located in slot A1).
Both CPUs will establish communication and CPU2 will temporarily become
SYSCON (as indicated by the green LED on the CPU) to do a diagnostic test
to ensure it can drive the VME bus.
This diagnostic test will switch the SYSCON between both CPU1 and CPU2
three times before proceeding.
After this diagnostics test is completed, the CPUs will determine if the GAP
application on both CPUs is the same.
If they have the EXACT same application CPU1 (located in slot A1) will be
SYSCON and initialize the I/O.
CPU2 will wait at a rendezvous point for the SYSCON CPU to be ready.
When the SYSCON CPU is ready it will turn out IO_LOCK (as indicated by
the LED on the CPU) and start running the GAP application.
After the SYSCON starts running the real-time code, the CPUs will start
sharing data.
If the SYSCON CPU fails, the Backup CPU will take over running the GAP
application and the I/O.

Vertex-Pro Motor-Driven Compressor Control Manual 26489V1
6 Woodward
If the CPUs do not have the same application, CPU1 (located in slot A1) will
become the SYSCON and start up in the SIMPLEX mode (see section Only
One CPU) with the Backup failed flag set to TRUE. (see picture of
CHAS_STAT block)
Single CPU operation (Simplex)
If only one CPU is started (or the second CPU is started 20 seconds after the
first CPU) this CPU will start up in the SIMPLEX mode.
When this occurs the CPU (in A1 or A14) will remove the WATCHDOG then
wait 20 seconds for the second CPU then continue with normal SYSCON
start-up of initializing the I/O and running the real-time application.
When the 2nd CPU is started, it will determine the other CPU is running and
ask the SYSCON to allow it to sync-in.
The SYSCON CPU will communicate with the BACKUP and if the BACKUP
has the EXACT same application and is functioning properly, the SYSCON
will allow the BACKUP CPU to sync.
If the BACKUP syncs in correctly, the backup fault indication in the GAP will
go FALSE (see Figure 2-7).
2.4—Vertex-Pro Simplex
2.4.1 System Diagram
Vertex-Pro Simplex
MicroNet 8 VME Slot Chassis
Single CPU for simplex operation
Motorola PowerPC CPU5200
Simplex I/O modules
Simplex Power
Redundant smart fans
FAN_2
FAN_3 FAN_4
Blank
FAN_1
Blank
A3
Blank
A4
Blank
A5
48/24 Discrete I/O
A6
Blank
A7
24/8 Analog I/O
A2
2-Slot
Power
Supply
PS1
Blank
PS2
A8
CPU5200
A1
2.4.2—Simplex Power Supplies
Single power supply provides power to the motherboard, CPU and I/O modules.
The MicroNet Plus power supply is 2-slot wide and are located at left end of the
chassis in the designated PS1 slot.
2.4.3—Single CPU Options
The MicroNet Plus control system may be used in simplex mode with a single
CPU5200 module that must be located in slot A1 of the main chassis. No other
options are available.
The CPU5200 module offers high processing capability in a PowerPC 5200
processor with features like dual Ethernet, dual Real Time Network ports, dual
CAN, and a configurable RS-232/RS-422/RS-485 serial port. Module operating
temperature limits are –40 to +85 °C.

Manual 26489V1 Vertex-Pro Motor-Driven Compressor Control
Woodward 7
2.4.4—Simplex Inputs and Outputs
Each I/O module has connectors on the faceplate. For analog and discrete I/O,
cables connect the module to a Field Terminal module (FTM). The FTM is used to
connect to the field wiring. For communications on the CPU, FTMs are not used.
Cables are connected directly to the faceplate of the communications on the CPU.
The following diagram shows the flow of analog and discrete inputs from the field
to the application.
Figure 2-4—Input Flow
Figure 2-5—Output Flow
2.4.5—Redundant Inputs
One level of redundancy is available. This involves wiring two external input
devices to two separate input channels. See Figure 2-7. In the event of a failed
sensor or a failure in the connection from the sensor to the control, a valid input is
still available
Figure 2-6—Redundant Sensors
The second level is wiring two external input devices to two separate I/O modules.
See Figure 2-8. In the event of a failure in one of the sensors, connections, cables,
FTMs, or I/ O modules, a valid input is still available.

Vertex-Pro Motor-Driven Compressor Control Manual 26489V1
8 Woodward
2.5—Vertex-Pro Simplex Operation
To use the MicroNet Plus for simplex operation, the CPU must be in the first user
slot (slot A1).
In the GAP application, select the MICRONET8 chassis and use the
CPU5200 in slot A1.
The CPU can only be the CPU5200.
Assign communication and I/O modules according to your application needs.
Compile and code your application using the Woodward GAP/Coder tools.
Use the AppManager Service Tool to load and start the application over
Ethernet.
After starting the application, the CPU will initialize the I/O and run the real-
time application.
System initialization is complete when all the I/O module fault LED's are
cleared.
2.6—Module Replacement
Chapter 9 contains Installation and Replacement procedures for VME Modules,
power supplies, relay boxes, and other devices. Individual CPU and I/O module
sections in Chapters 5 through 7 are an additional reference for installation and
replacement information.
Sections 4.2 contain additional details for power supply installation and
replacement. Note that power must be removed from the power supply input
before a module is removed or inserted.
BEFORE REMOVAL
!RESET
MODULE
Live insertion and removal of the CPU5200 is allowed in a MicroNet
Plus chassis. These modules should be reset immediately before
removing them from the chassis. This notifies the module that it will
be removed and provides a graceful failover to another healthy CPU
module if available.
2.7—Latent Fault Detection
Because a redundant system can tolerate some single faults, it is possible for a
fault to go undetected. Undetected faults are termed latent faults. If another fault
occurs when a latent fault exists, the second fault could cause a shutdown. It is
important to detect a latent fault in a redundant system so that it may be repaired
before another fault occurs. Without a fully triplicated system it is not possible to
detect all latent faults, however most faults can be detected. For single or
redundant I/O points, fault detection is dependent on the application software to
detect its I/O faults.

Manual 26489V1 Vertex-Pro Motor-Driven Compressor Control
Woodward 9
The Vertex-Pro fault information available from the CHASSIS status block.
Figure 2-7—CHAS_STAT Block
REQ_FOVER is used when making BACKUP CPU change SYSCON
manually. This is effective only within DEBUG mode.

Vertex-Pro Motor-Driven Compressor Control Manual 26489V1
10 Woodward
Chapter 3.
Chassis
3.1—MicroNet Plus 8-Slot Chassis
Figure 3-1—MicroNet Plus 8-Slot I/O Chassis
The MicroNet Plus 8-slot chassis offers redundant CPU capability and more I/O
slots, as well as improvements in airflow and overall system reliability.
Features:
A total of 8 CPU and I/O slots are available for use
A new 2-slot wide, redundant, load sharing power supply is used
Redundant Smart fans are used for early notification of fan-failure
Chassis temperature switches are built into the motherboard and trip at
+65 °C
Redundant, hot-swappable CPUs are supported